VW T3 Locking Syncro Gearbox and Front Locking Differential Rebuild. According to some the Holy Grail of VW T3 Syncro Gearboxes also with its matching Locking front Differential. This just left today . Lets start with the gearbox.
VW T3 16″ Syncro Gearbox
AVR type 094 4×4 Difflock 5.43 final drive 2.1 petrol 16”
Heavy Case with reinforcements for oiling plates
V gear box 9/17 mainshaft 094311101D and 2nd gear z =32 094311261B
Gear ratios g gear 6,03 1st 3,78 2nd 1,88 3rd 1,23 4th 0,85
Rev 6,03 Final drive 5,43 Lockable VC
Crown and pinion exchanged for excellent second hand from stock with a new Pinion Bearing fitted FAG Hungary
1st gear
Reconditioned bearing with new rollers, 247b syncro ring
Excellent 8/10 1/2 syncro hub
new 295A syncro ring
2nd gear,
3rd gear oil face down (0,05-0.2 oil gap desired ) 0.1mm gap measured with silver circlip for 3rd gear
4th gear oil ring up
New pinion bearing lock ring torqued to 210nm and synched
Crown Wheel
New differential Bearings installed Timken
Crown wheel and Diff faces cleaned Crown wheel heated and dropped onto Diff Crown Wheel bolts Torqued to 50nm and checked when cold
Excellent used mainshaft with resurfaced bearing surface
2 new 3rd and 4th gear 02A 311 265 D needle bearings installed VW
3rd gear reused
Excellent used 4th gear used
new syncro rings 295A installed
Aluminium seal installed
New Mainshaft Bearing FAG installed
AJT Mainshaft bearing plate installed
New shift rail bearings installed Roulex
4th gear oiling plate installed
All gears mesh Yes
Mainshaft bearing 002311125A installed in main case and circlip
Case re-sleeved for relay lever and relay lever in
New selector shaft bush installed
All case holes tapped and faces cleaned
New paper gasket
Ball valve and shift rod cover installed
Green spacer replaced with black oil gap 0.5mm
Refurbed R gear needle bearings installed with new needle bearings
New G gear NTN roller bearings installed
New INA 93463.1 bearing for reduction gear
Thrust washer 1.2 mm
Skimmed reduction housing with new pinion bearing 373
Rev idler installed with shortened shaft and refurbed needle bearings installed
All case holes tapped and faces cleaned
New diff lock sleeve O ring
Oiling plate installed
Input shaft installed with new circlip
Backlash = 17 +/- 2 readings should be between 0.15-0.25 and readings should not differ by more than 0.05
New Bell housing paper gasket
HD RjES clutch fork installed with Weddle HD Bronze bush, new bonze bush in bellhousing, and new circlips
New input shaft seal and new INA clutch guide sleeve
New output shaft seals and o rings
New Cortecco double lipped Prop output seal
New selector Shaft Seal better one with spring garter installed
Output flanges installed with new circlips and bungs
New ball, washer and Nylock nut and boots.
Clutch fork (petrol) installed with new circlip
Rev Housing installed with new O ring and paper gasket
G idler installed wit new O ring
Rev idler cover installed with sealant
Output flange nutand washer installed and torqued to 160 nm
All gears select
Diff lock moves freely and pin is the right way up
Front lockable Differential
Gearbox ADM # 06 03 8 1998 box
Pinion Bearing new FAG Hungary
Lock ring torqued to 210nm and stop tab folded over.
R= 63.39 mm RM = 63.40mm tolerance is +/- 0.05mm so good
S3 shim changed to 0.76mm shim
New Diff bearings Timken Poland, preloaded and run in at 47nm
New input shaft bearings SKF 6206 and 6007
New Double needle spigot bearing for output shaft INA HK 1622 Germany
Cortecco input flange seal double lipped
Pinion bearing lock ring synched
Backlash 0.17 +/- 2 readings should be between 0.15-0.25 and readings should not differ by more than 0.05
Red 19 tooth speedo moves freely in sleeve with new seal
Installed with a reconditioned Viscous Coupling (exchange) from Holman engineering
All case holes tapped and faces cleaned no gaskets used in Diff faces joined with Wurth super RTV Sealant
All threads cleaned on bolts
New output shaft seals and O rings
Input flange nut and washer installed and torqued to 160 nm
New Diff lock seal, Diff lock pin moves freely and is the right way u.
Thats all for today folks, got an extra special one on the way bt you’ll just have to wait for that one :)
Any enquiries, info or bookings give a shout here https://vantopia.ie/contact/,